Device for removing debris from passages in manufactured modular blocks
A device for removing concrete debris from passages within modular blocks is disclosed. The device includes nozzles mounted to a plate at locations corresponding to the passages on the modular blocks. An actuator is secured to the block molding machine, supports the plate, and moves the plate from a retracted position to an extended position in close proximity to the conveyor. The nozzles are operatively connected to a source of compressed air and are arranged to enter within the passages of the modular block when the plate moves to the extended position. A control system directs operation of the device such that when a modular block reaches a predetermined location on the conveyor, the actuator moves the mounting plate to the extended position causing the nozzles to enter within the passages of the modular block and emit jets of compressed air to remove concrete debris from within the passages.
“Not Applicable”
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT“Not Applicable”
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK“Not Applicable”
FIELD OF THE INVENTIONThis invention relates generally to the manufacture of concrete blocks. More specifically, this invention relates to a device for removing debris from passages in manufactured modular blocks, such as wallstones.
BACKGROUND OF THE INVENTIONModern, high speed, automated concrete block plants and concrete paver plants make use of concrete block molds that are open at the top and bottom. These molds are mounted in machines which cyclically station a pallet below the mold to close the bottom of the mold, deliver dry cast concrete into the mold through the open top of the mold, densify and compact the concrete by a combination of vibration and pressure, and strip the uncured blocks from the mold by a relative vertical movement of the mold and the pallet. Once the blocks are stripped from the mold they are protected until they are sufficiently hardened to permit handling without damage. The concrete blocks thus hardened are cured in a curing yard to permit complete moisturization for at least twenty-one days.
For efficient high-volume production, concrete block molds are typically configured to produce multiple blocks simultaneously. A concrete block mold generally comprises side walls and end walls that define the periphery of a mold cavity. Within this mold cavity, division plates may be used to sub-divide the mold cavity into a plurality of block-forming cavities. Further, movable side walls may be used to form the side faces of the block-forming cavity. The division plates are generally rectangular-shaped plates attached to the side walls of the mold. Further, the side walls of the block cavity and the division plates may be covered with replaceable mold face linings to protect the mold components from abrasive wear.
Concrete blocks fabricated by the automated processes described above are often used in the construction of vertical walls, such as sitting walls, or set-back retaining walls for securing earth embankments against sliding and slumping. The blocks, often referred to as wallstones are stacked on each other and located in rows to form a wall. The wall structure can have a variety of shapes, such as linear, concave, and convex curved, serpentine and circular to conform to the landscape utilization. Each wallstone may have one or more attractive and decorative faces. The decorative faces can be smooth, serrated, horizontally grooved, vertically grooved, diagonally grooved, checkerboard or have an aggregate appearance. The front face of the block can be broken apart concrete or broken irregular pattern. The wallstone may be of any desired color including gray or earth tones and the like.
Each wallstone may have a generally flat top and bottom surface so that the rows of wallstones can be stacked or superimposed on top of each other. The adjacent rows of blocks may be connected together with rods or pins. Each block has one or more passages extending from the top surface to the bottom surface to accommodate the rods or pins. Rows of wallstones overlap each other so that each wallstone is pinned to adjacent wallstones located in adjacent courses of wallstone above and below. Multiple passages may be provided to the wallstones to add versatility so that each wallstone may be used in the construction of a vertical wall or a set-back wall.
For example, the wallstone may be fabricated to be versatile by providing six passages, four to be utilized for the construction of a set-back wall and two to be utilized for the construction of a vertical wall. To construct a set-back wall, after a first layer of wallstone is set and leveled in all directions to create a base, a subsequent course is added such that the two front passages of the subsequent layer wallstones are aligned above a pocket (also referred to as an “offset pocket”) located in the wallstones in the course below, to create a slight offset. After the wallstones are set and visually aligned, pins are dropped in these two holes and into the pockets in the wallstones of the base layer. This process is repeated as subsequent courses are added above previous courses to construct a set-back wall. In this manner, the wallstones become interlocked together, adding strength and integrity to the overall wall structure. To construct a vertical wall, the two passages located in the pocket of the wallstones of the subsequent course are aligned above the pocket of the wallstones in the previous course, and pins are dropped in these two holes and into the pocket in the wallstones of the previous course.
A common drawback is that during fabrication of the wallstones, debris created during the fabrication process can become lodged in the passages. If not removed quickly, the debris will cure within the passages and create obstructions therein, thus preventing use of the interlocking feature of the wallstones. Currently, the method for cleaning the passages of such debris involves manually inserting a dowel into each of these passages after the wallstone is stripped from the mold within the production environment and which adds to the overall cost and increases safety concerns. Such manual debris removal from the passages has other disadvantages. It is a delicate operation requiring a certain amount of dexterity to avoid damaging the passages of uncured wallstones. Also, the current manual cleaning requires added labor expressly dedicated to this particular task to keep pace with the high volume of wallstone being produced by the automated process. Thus, the debris removal device of the present invention offers significant advantages over the current manual cleaning described above. The debris removal device of the present invention is operative to direct a flow of pressurized fluid, such as air through a plurality of outlets and through the passages of wallstones as the wall stones are conveyed after being stripped from the mold. The device of the present invention is automated and may be integrated into the concrete block manufacturing process, thus eliminating the need for increased labor. Also, the device of the present invention can remove debris from multiple passages simultaneously to keep pace with the rate of automated production. Also, the device will substantially reduce the potential for damage to the wallstone passages.
SUMMARY OF THE INVENTIONA device for removing concrete debris from passages within modular blocks is disclosed. The device includes nozzles mounted to a plate at locations corresponding to the passages on the modular blocks. An actuator is secured to the block molding machine, supports the plate, and moves the plate from a retracted position to an extended position in close proximity to the conveyor. The nozzles are operatively connected to a source of compressed air and are arranged to enter within the passages of the modular block when the plate moves to the extended position. A control system directs operation of the device such that when a modular block reaches a predetermined location on the conveyor, the actuator moves the mounting plate to the extended position causing the nozzles to enter within the passages of the modular block and emit jets of compressed air to remove concrete debris from within the passages.
Referring now in greater detail to the drawings in which like numerals represent like components throughout the several views, the process for molding a concrete block such as a wallstone is described. Referring to
An example of a block made from the molding process described above is indicated at 70 in
The top 82 has a pair of score lines or recesses 102 and 106 that are used to split the block 70 into two separate blocks. The score lines 102 and 106 allow the block 70 to be split into two blocks with the score lines 102 and 106 being centered on the wider or front face 74. The top 82 also has a pair of offset pockets 110 and 114 formed therein. The offset pockets 110 and 114 are used to construct a retaining wall structure in a tiered formation with each tier being setback or offset from each other. The pockets 110 and 114 provide for a predetermined or preselected distance that each of the tiers will be setback. As best shown in
With reference now to
As can be appreciated, the blocks 70, 204, 208 and 212 along with the pavers 220, 221, 232 and 236 of the present invention are formed in the mold box 200. Generally, the process entails molding the blocks 70, 204, 208 and 212 and the pavers 220, 221, 232 and 236 by using a mixture of cement and water and other materials, as described above. The blocks 70, 204, 208 and 212 and the pavers 220, 221, 232 and 236 are fabricated by compressing and vibrating the mixture in the mold box 200 by the application of pressure to the mixture by use of a block molding machine as described above. It is also known to use a press head having a press plate for applying pressure to the mold box 200. Further, the press plate may include structure that forms the shallow grooves, the indicators, and the markings in each of the blocks 70, 204, 208 and 212. Also, an insert bar may be used to form the passages 116, 126, 130, 142, and 146 and the offset pockets 110 and 114 in each of the blocks 70, 204, 208 and 212. Once the blocks and pavers are formed they may be cured through any method known in the art. For example, curing may take the form of air curing for a number of days or steam curing, but normally one day is allowed or needed for cure.
As discussed previously, debris created during the fabrication process can become lodged in the passages 116, 126, 130, 142 and 146. It is not uncommon for debris to accumulate within these passages to a depth of two inches or greater. If not removed quickly, the debris will cure within the passages and create obstructions therein, thus preventing use of the pins 248 and 252 for creating an offset or setback of courses of the wallstones. Under the present invention, a device is provided for injecting air within the passages so that loose concrete particles within the passages can be flushed out so the passages are useable for the purposes mentioned above.
Referring now to
Referring now to
A pair of opposed stationary guides 300 are provided for guiding and positioning the finished block 292 as it is conveyed in the direction of travel indicted by arrow 303 over the debris removal device 302 of the present invention. The guides 300 include a slightly tapered configuration at the inlet end to precisely align the finished block as it is conveyed over the debris removal device 302. Each opposed guide 300 is affixed, e.g., welded, to an angle-iron support beam 304, which in turn is affixed, e.g., welded, to a vertical support post 306, having a generally square cross-sectional shape, as best shown in
Referring now to
Referring now to
Referring to
For example, as the support slat 294 continues to move with the conveyor belts 296, an encoder (not shown) may transmit pulses to a processor (not shown) at a predetermined time interval, the processor keeping count of the number of pulses received from the encoder. By knowing the speed of the conveyor belts 296 and knowing the count of pulses received from the encoder, the location of a slat 294 supporting a finished block 292 may be determined with a high degree of accuracy. In this manner, a predetermined count of pulses received by the processor, e.g., 1124 pulses, may be associated with a slat 294 supporting a finished block 292 reaching a predetermined position over the debris removal device 202, as best shown in
Simultaneously, upon reaching the predetermined position, the processor may send a signal to energize a solenoid (not shown) to deliver pressurized air to inflate the air bellows 386 which lifts the rectangular plate assembly 346 upwardly from the retracted position to the extended position, whereupon the air nozzles 378 enter the passages 292a of the block 292. In
It is understood that the device for removing debris from passages of manufactured modular blocks of the present invention and its constituent parts described herein is an exemplary indication of a preferred embodiment of the invention, and is given by way of illustration only. In other words, the concept of the present invention may be readily applied to a variety of preferred embodiments, including those disclosed herein. While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
Claims
1. A device for removing concrete debris from passages within modular blocks that have been formed by a block molding machine, the block molding machine including a mold, a conveyor for transporting modular blocks after molding, and a framework, each modular block including a top, a bottom, a front face, a back face, a first side, and a second side, the passages extending the entire height of the block from the top to the bottom, said device for removing debris comprising:
- a. a plate having mounting holes defined therein and corresponding with the location of the passages on the modular blocks;
- b. an actuator secured to the framework of the block molding machine and supporting said plate, said actuator operative to move said plate from a retracted position to an extended position in close proximity to the conveyor;
- c. nozzles mounted within the mounting holes of said plate and operatively connected to a source of compressed air, said nozzles arranged to enter within the passages of the modular block upon movement of said plate to said extended position; and,
- d. a control system to direct operation of said device for removing debris, such that upon a modular block reaching a predetermined location on the conveyor, said control system energizes said actuator to move said mounting plate to said extended position causing said nozzles to enter within the passages of the modular block and emit jets of compressed air to remove concrete debris from within the passages.
2. The device for removing debris of claim 1, wherein said actuator is secured to the framework beneath the conveyor.
3. The device for removing debris of claim 1, wherein said actuator is a bellows chamber operatively connected to a source of compressed air.
4. The device for removing debris of claim 1, wherein the passages of the block are arranged in a predetermined configuration, and wherein said nozzles are mounted within said mounting holes of said plate at locations matching the predetermined configuration.
5. The device for removing debris of claim 1, wherein the manufactured modular block includes passages located within offset pockets located in the top of the manufactured modular block, and wherein said mounting holes correspond with the locations of the passages within the offset pockets.
6. The device for removing debris of claim 5, wherein the manufactured modular block includes a pair of grooves located on either side of the offset pockets, the pair of grooves extending across a portion of the top of the block and wherein a passage is located within each groove, and wherein said mounting holes correspond with the location of the passages within each groove.
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Type: Grant
Filed: Mar 5, 2014
Date of Patent: Oct 27, 2015
Patent Publication Number: 20150251334
Inventor: Michael Coggin (Telford, PA)
Primary Examiner: David Redding
Application Number: 14/198,025
International Classification: A47L 5/38 (20060101); B28B 11/22 (20060101);